System and method for increasing the surface mounting stability of a lamp

ABSTRACT

In one embodiment, an LED is constructed with its entire contact structure is stamped and inserted into the molded lamp as a single structure. A portion of the contact structure is imbedded in the molded lamp such that the bottom surface of the contacts do not extend below the base of the molded lamp. The base of the molded lamp is made wide enough to give support to the entire structure. Using this concept, any excess contract structure is cutoff and there is no need for bending of the contract structure to form the contact portions. In some embodiments, the cross-sectional area of the lamp base is extended to increase stability of the lamp when the lamp base is mounted on a flat surface.

BACKGROUND

It is now common practice to mount lamps, such as LEDs, on flat surfacessuch as substrates. LEDs, particularly those designed for surfacemounting have shells that are typically cylindrical in shape with thetop portion formed to allow light from the LED elements to escape.Contacts, typically constructed from a metal stamping, extend outwardfrom the bottom portion of the lamp shell. These contacts add height tothe structure and thus are not practical where space is limited.

In addition, in order to gain stability for the lamp (i.e., preventingthe lamp from wobbling or being mounted in a “tipped” position), theremust be a relatively wide physical connection between the lamp and themounting surface. To achieve such stability it is necessary to bend thecontacts to form pads for support purposes. Such bending is costly froma manufacturing point of view and unless each contact of a lamp isprecisely bent, so that the bottom surfaces of each contact are in thesame plane, the lamp will tip one way or the other.

SUMMARY

In one embodiment, an LED is constructed such that its entire contactstructure is stamped and inserted into a lamp shell as a singlestructure. A portion of the contact structure is imbedded in the lampshell such that the bottom surface of the contacts do not extend belowthe base of the lamp shell. In one embodiment, the base of the lampshell is made wide enough to give support to the entire structure. Anyexcess contract structure is cutoff and there is no need for bending ofthe contract structure to form the contact portions. In someembodiments, the cross-sectional area of the lamp base is extended toincrease stability of the lamp when the lamp base is mounted on a flatsurface.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, reference isnow made to the following descriptions taken in conjunction with theaccompanying drawing, in which:

FIG. 1A shows one embodiment of the invention in which the lamp shell isseparate from the contact structure;

FIG. 1B shows the contact structure mated with the lamp shell;

FIGS. 2A and 2B, 3A and 3B show alternate embodiments of the contactstructure of the present invention;

FIG. 4 shows an alternate embodiment of the lamp shell having legsthereon;

FIGS. 5A and 5B show an alternate embodiment where the legs extendcircumferentially from the lamp shell; and

FIGS. 6 and 7 show examples of prior art lamps and the contactsextending therefrom.

DETAILED DESCRIPTION OF THE INVENTION

Prior to beginning the description of the concepts of the instantinvention it might be well to look at examples of prior art with respectto FIGS. 6 and 7. FIG. 6 shows LED 60 which has lamp shell 61 andcontacts 62 extending from the base of the lamp shell. As noted,contacts 62 are bent so as to form a platform to allow both electricalcontact and stability of the lamp. Note that if the contacts are notbent exactly evenly then the lamp shell 61 will tilt one way or theother, thereby changing the intensity of the light in an unwantedmanner. Similarly, lamp 70 shown in FIG. 7 has long legs of contactswhich could either be extended through a circuit board or mounted on thesurface by bending the legs one way or another. device 70 suffers fromthe same problems as does device 60.

Turning now to FIG. 1A, there is shown LED device 10 which could be anSMT based lamp. Contained within shell 17 are the elements, such aselements 19, which make the LED light work properly, including, ifdesired, focusing elements. Contact structure 13 has top areas 18 forcontacting with elements 19 within shell 17. Contact structure 13 alsohas contact area 11 which has a bottom surface 12 and side contact areas11A and 11B. Contact structure 13 is manufactured in one embodiment by asingle stamping process and when contact structure 13 is mated insideshell 17, bottom surface 12 lies parallel to or above bottom surface 100of shell 17 as shown in FIG. 1B. Light from the enabled LED shines fromtop 15 of shell 17.

As shown in FIG. 1B, contact portions 11 a and 11 b extend from slots102 in shell 17. Once contact structure 13 is fully mated within shell17 it can be cut along dotted line 101 for electrical and mechanicalisolation. Shell 17 provides the structure to hold the contacts and theelements associated therewith steady. At the same time the contacts areeither flush with the bottom surface of shell 17 or above the bottomsurface. Thus, bottom surface 100 of shell 17 provides stability formaintaining the LED in the proper orientation such that top 15 ispositioned in the desired plane. Bottom area 100 of shell 17 can beexpanded, for example, by extension legs 14 to provide a wider surfacearea to increase stability.

FIG. 2A shows alternate contact structure 20 using narrowly formedcontact areas 23 and contacts 21 and 22 extending perpendicularlyoutward from risers 23. The bottom surface of extensions 21 and 22 formthe contacts in the finished structure as shown in FIG. 2B. Afterstructure 20 is mated with shell 17 structure 20 can be cut along line201 so that portions 23 and 24 can fall away. During manufacture,portion 24 maintains the stability and rigidity of structure 23 so thatit can be inserted properly within shell 17.

FIG. 3A shows an alternative contact structure 30 where contacts 31 and32 are formed on riser sections 35. Again, riser sections 35 and base 36are cut off along cut off line 301 when structure 30 is mated with shell17 (FIG. 3B).

FIG. 4 shows an alternative embodiment 40 having shell 41 with contacts31 and 32 extending circumferentially outward therefrom as discussedabove. Shell 41 also has two legs, 42 and 43, extended below (above inFIG. 4) base surface 40 so that the base of these legs, or feet, are inthe same plane as the bottom of contacts 31 and 32 so as to provideadditional support. There can be as many legs as desired to form a planeand the legs and be molded as a part of shell 41 as desired.

FIG. 5A shows alternative contact structure 50 where the contactstructure can have feet, such as feet 51 a and 52 a that extend outwardeven further than the outer circumference of shell 52 (FIG. 5B) suchthat when contact structure 50 is mated inside shell 52, feet 51 a and51 b extend circumferentially outward to increase stability. Also notethat base portion 53 of lamp shell 52 can be made larger than the bodyof the shell. By making the bottom surface of contacts 51A and 51B flushwith bottom surface 500 of shell 52, added support and structuralstability is imparted to the device when it is mounted on a flatsurface. Structure 50 can, if desired, be constructed in a singlestamping and excess material 501 can be cut away once structure 50 ismated with shell 52.

Although the present invention and its advantages have been described indetail, it should be understood that various changes, substitutions andalterations can be made herein without departing from the spirit andscope of the invention as defined by the appended claims. Moreover, thescope of the present application is not intended to be limited to theparticular embodiments of the process, machine, manufacture, compositionof matter, means, methods and steps described in the specification. Asone of ordinary skill in the art will readily appreciate from thedisclosure of the present invention, processes, machines, manufacture,compositions of matter, means, methods, or steps, presently existing orlater to be developed that perform substantially the same function orachieve substantially the same result as the corresponding embodimentsdescribed herein may be utilized according to the present invention.Accordingly, the appended claims are intended to include within theirscope such processes, machines, manufacture, compositions of matter,means, methods, or steps.

1. A method of manufacturing an LED, said method comprising: inserting apremolded set of contacts into an LED molded lamp such that at least aportion of said contact set extends from the base of said molded lamp;and cutting away any said portion of said contact set that extendsbeyond said molded lamp base.
 2. The method of claim 1 wherein saidinsertion is such that a portion of said contact set extends beyond acircumferential edge of said molded lamp.
 3. An LED comprising: apremolded lamp shell having contained therein LED structure adapted formating with electrical contacts, said lamp shell having a base with anarea for receiving said electrical contacts; at least one set ofcontacts formed on a single structure and adapted to be inserted insidesaid lamp shell via said lamp base, said set of contacts having at leastone laterally extending portion, said laterally extending potion forextending circumferentially outward of said lamp base and said laterallyextending portion having a bottom surface adapted to not extend belowthe lower surface of said lamp base.
 4. The LED of claim 3 wherein saidlamp shell is circular.
 5. The LED of claim 4 wherein said lamp base hasa portion with a circumference larger than the circumference of the mainportion of said lamp shell.
 6. The LED of claim 5 wherein said widercircumference is large enough to provide stability for mounting said LEDto a substrate.
 7. The LED of claim 3 wherein said premolded lamp shellbase has constructed thereon at least one protruded leg for providingstability for mounting said LED to a substrate.
 8. The LED of claim 7wherein the base of said protruded leg is on the same plane as the baseof said laterally extending portion.
 9. A structure for use in providingelectrical power to a lamp wherein said lamp has a base for mounting ona substrate; said structure comprising: a formed set of electricalcontact leads, said contact leads having contact portions for matinginternal to said lamp with elements within said lamp requiringelectrical power and contact portions extending circumferentiallyoutward of said lamp when said internal contact portions are in properinternal mating relationship.
 10. The structure of claim 9 wherein saidstructure further comprises: a portion adjacent to said external contactportion adapted to be cut away leaving a bottom surface of saidoutwardly extending contact portion substantially flush with a bottomportion of said lamp when said internal contact portions are in properinternal mating relationship.
 11. The structure of claim 10 wherein saidlamp is an LED and wherein said internal elements requiring power areelements of said LED.
 12. The structure of claim 11 wherein said bottomportion of said lamp has a surface area great enough to maintainstability of said lamp when said bottom portion of said lamp is mountedon a substrate.
 13. The structure of claim 12 wherein said bottomportion of said lamp further comprises: at least one pad for increasingsaid surface area.
 14. The structure of claim 12 wherein said at leastone pad operates in conjunction with said bottom surfaces of saidoutwardly extending contact portions to increase said stability.
 15. Thestructure of claim 12 wherein said bottom surface of said lamp has agreater cross-sectional area than does the top portion of said lampwhere said LED is positioned.
 16. The structure of claim 10 wherein saidstructure has at least a pair of support elements running parallel tothe longitudinal axis of said lamp and wherein said externally extendingportion is a portion of the width of said parallel running portion. 17.The structure of claim 10 wherein said structure has at least a pair ofsupport elements running parallel to the longitudinal axis of said lampand wherein said externally extending portion is a portion extendingoutward from said parallel running portion.
 18. A lamp shell comprising:a cylindrical portion having a top for allowing light to escape; a baseportion for mounting on a substrate; said base portion having a lowersurface having a cross-sectional area large enough to maintain said topportion stable when said bottom portion is in contact with a flatsurface; said base portion comprising: means for receiving a contractstructure, said contract structure having a proximal end for mating withlight producing elements within said lamp shell and externally extendingportions for extending circumferentially outward from said base portionfor receiving electrical power from an external source; and at least twoareas positioned to receive and support said externally extendingportions such that the bottom edge of said externally extending portionsdo not extend below said base lower surface.
 19. The lamp shell of claim18 wherein said bottom edge of said externally extending portionsoperate in conjunction with said base lower surface to increase saidstability of said lamp top portion when said base portion is in contactwith said flat surface.
 20. The lamp shell of claim 19 wherein saidreceiving means comprises at least a pair of slits on oppositecircumferential edges of said lamp base.